Sealed actuator with internal clutching

ABSTRACT

A sealed actuator with internal clutching assembly including an output shaft, output detent ring, moving detent ring, and a wave spring, which is fit inside a sealed housing. The moving detent ring is able to move axially to the output shaft and the output detent ring is able to rotate on the output shaft. Intermeshing ramped teeth of these rings are held together by a wave spring and allow the output shaft to rotate and transmit torque of a motor through a main gear operably coupled to an output gear mounted on the output shaft to the outside of the housing. During predetermined high loads, the output and moving detent rings ramped teeth create an axial force that overcomes the load from the wave spring, which allows moving detent ring to disengage and output shaft to rotate freely to help prevent damage to the actuator.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a National Stage of International Application No.PCT/US2014/043185, filed Jun. 19, 2014. This application claims benefitof U.S. Provisional Patent Application No. 61/836,936 filed Jun. 19,2013. The disclosures of the above applications are incorporated hereinby reference.

FIELD OF THE INVENTION

The present invention relates to a clutch system for use in an actuatorassembly for a vehicle.

BACKGROUND OF THE INVENTION

Clutched actuator assemblies to fold a vehicle mirror are known. Thesemechanisms are known to have many disadvantages and are also not robustenough for particular applications. Generally, the actuator is a hingedactuator with a base that must be fixed and an upper half that providesthe movement of 80 degrees only. This base and upper half also moveapart during clutching. Known actuators are not waterproof, do not meetcycle requirements, and do not meet requirements for other more robustassembly needs such as are necessary in vehicle aerodynamic structures.Conventional actuators do not have the combination of the desiredattributes of a high cycle life, safety overload clutch, beingwaterproof, and holding torque capacity.

Therefore, it is desired to provide an actuator assembly that providesan actuator which is protected from environmental elements in vehicleunderbody environments, has improved cycle durability, can drive in bothdirections, holds its position when stopped, has pass through drive, andhas a clutch system to protect the actuator under higher predeterminedloads.

SUMMARY OF THE INVENTION

The present invention is directed to a sealed actuator with internalclutching assembly. There is provided a clutch system comprising anoutput shaft, output detent ring, moving detent ring, and a wave springlock, which is fit inside a sealed two-part housing. The moving detentring is able to move axially to the output shaft and the output detentring is able to rotate on the output shaft. Intermeshing ramped teeth ofthese rings are held together by the wave spring lock and allow theoutput shaft to rotate and transmit torque to a motor through a maingear operably coupled to an output gear held by the output shaft to theoutside of the two-part housing.

The actuator is operable to drive in both directions, but when stoppedwill hold its position without back driving when subjected to a loadmany times greater than its dynamic range. The actuator will alsoprotect itself from damage from predetermined loads, very highpredetermined loads, due to the clutch system that will disengage thedrive system allowing it to rotate. During a predetermined high loadcondition, the output and moving detent rings ramped teeth create anaxial force that overcomes the load from the wave spring, which allowsthe moving detent ring to disengage and the output shaft to rotatefreely to help prevent damage to the actuator.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating the preferred embodiment of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1 is a perspective view of a clutch system for an actuatorassembly, in accordance with the present invention;

FIG. 2 is a perspective view of an actuator with internal clutchingassembly with a housing and motor arrangement removed for clarity, inaccordance with the present invention;

FIG. 3 is a perspective view of the sealed actuator with internalclutching assembly with a housing removed for clarity, in accordancewith the present invention;

FIG. 4 is an exploded view of the actuator with internal clutchingassembly, in accordance with the present invention;

FIG. 5 is a partially broken away perspective view of a vehicle enginecompartment having an active grille attached, as an example of anenvironment of use of an actuator with internal clutching assembly, inaccordance with the present invention; and

FIG. 6 is a partially broken away sectional plan view of an activegrille system, as an example of an application of use with the actuatorwith internal clutching assembly, in accordance with the presentinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiment(s) is merelyexemplary in nature and is in no way intended to limit the invention,its application, or uses.

There is provided a sealed actuator with internal clutching assembly inaccordance with the present invention which provides desirable highercycle durability and capability combined with a water tight arrangementfor use, by way of example, in underbody environments exposed to theelements. The sealed actuator with internal clutching assembly furtherprovides a safety override clutch system which allows the actuator torotate under predetermined conditions, e.g., predetermined high loads,to help protect a motor and other components of the actuator withinternal clutching assembly, as will be explained in greater detailbelow. When subjected to abnormal loads or a predetermined amount offorce or other predetermined conditions, the actuator with internalclutching assembly will move features out of the way to help preventdamage thereto.

Referring generally to FIGS. 1-4, a sealed actuator with internalclutching assembly is shown generally at 10, comprising a clutch system,generally shown at 12, and housing portion, generally shown at 14. Theclutch system 12 comprises an output shaft 16 which is received withinand holds an output detent ring 18 and a moving detent ring 20.

The output detent ring 18 is free to rotate on the output shaft 16 abouta portion of the output shaft 16 that is not splined. The moving detentring 20 is able to move axially to the output shaft 16 but is lockedradially by a plurality of interlocking splines 22, 24 on bothcomponents. The output shaft 16 has interlocking splines 22 that arearranged parallel to the longitudinal axis and operably spaced about anouter surface located on a lower half of the output shaft 16. The movingdetent ring 20 has outer interlocking splines 24 forming complementarychannels to slidably interlock with the interlocking splines 22 forcontrolled axial movement of the moving detent ring 20. The interlockingsplines 22 of the output shaft 16 terminate at an integrally formedprojecting ring 26 having an abutting surface 28, lying transverse tothe axis, against which the output detent ring 18 engages. The outputdetent ring 18 abuts against this surface 28 on the output shaft 16 anddoes not move axially.

An output gear 30 is in mesh with the output detent ring 18 fortransmitting torque. The output gear 30 has spaced circumferentialsegments 32 that are generally square teeth like shaped held in placewithin opposing recesses 34 of the output detent ring 18 fortransmitting the torque.

The output and moving detent rings 18, 20 have first and secondintermeshing ramped teeth, generally shown at 36, 38, respectively, thatare held together in mesh by the biasing force of a wave spring 40. Thewave spring 40 is received on the outer output shaft 16 and provides abiasing force against the moving detent ring 20 in the direction of theoutput detent ring 18.

The components of the clutch system 10 (e.g., output shaft 16, outputgear 30, output detent ring 18, moving detent ring 20, and wave spring40) are held together by first and second locking rings 42, 44 locatedtoward respective ends the output shaft 16 of the clutch assembly 12.

A motor 46 selectively provides torque suitable for particularapplications. Suitable electontronics 48 (e.g., a shut off printedcircuit board (PCB)) with connector contacts 50 correlate with vehiclecommunication networks and/or at least one sensor for commanding themotor 46 based upon predetermined conditions. By way of non-limitingexample, energizing of the motor correlating with vehicle speed.

The motor 46 has a worm gear, shown generally at 52, which causes a maingear, shown generally at 54, to rotate. The main gear 54 has a gear anda helix angle portion 58. The worm gear 52 has a shaft, e.g., a threadedshaft, which engages the teeth of the gear 56, which causes the gear 56of the main gear 54 to rotate as the worm gear 52 rotates. Rotation ofthe gear 56 causes the helix angle portion 58 of the main gear 54 toalso rotate. The helix angle portion 58 rotatably engages the outputgear 30. The gear ratio range of the gear 56 to helix angle portion 58is operably suitable for transmiting torque from the motor/worm gear46/52 to the output gear 30. The first and second intermeshing rampedteeth 36,38 of the output and moving detent rings 18,20 when heldtogether by the biasing force of the wave spring 40 lock and allow theoutput shaft 16 to rotate and transmit the torque of the motor 46through the main gear 54 and output gear 30 to the outside of thehousing portion 14. By way of non-limiting example, the output shaft 30is coupled to a component and/or coupled to a drive shaft forselectively rotating, folding or otherwise moving at least one componentlocated outside of the housing portion 14 between at least a firstposition and a second position. The wave spring 40 allows for a morecompact structure while meeting biasing and predetermined loadrequirements.

The housing portion 14 comprises a first half 60 and a second half 62.The first half 60 has a first clutch assembly cavity 64 and a firstmotor cavity 66. The second half 62 has a second clutch assembly cavity68, a main gear cavity 70, and a second motor cavity. The clutch system12 fits fully inside the first and second halves 60, 62 of the housing(within the first and second clutch assembly cavities 64, 68), as wellas the motor 46 and electronics 48/50 (within the first motor cavity 66and second motor cavity), and main gear 54 (within the main gear cavity70). The first and second halves 60, 62 of the housing portion 14 arejoined together, and connected with fasteners, and first and secondseals added 72, 74 onto the output shaft 16 to form a weathertighthousing.

In operation, the first and second intermeshing ramped teeth 36, 38 ofthe output and moving detent rings 18, 20, that when held together bythe biasing force of the wave spring 40, lock together and allow theoutput shaft 16 to rotate. This allows torque transmission from themotor 46/worm gear 52 through the main gear 54 and output gear 30 to theoutside of the housing portion 14 via the output shaft 16. During apredetermined level of high load, the first and second intermeshingramped teeth 36, 38 create an axile force that overcomes the load fromthe wave spring 40. This allows the moving detent ring 20 to disengageand allow the output shaft 16 to rotate freely, thereby preventingdamage to the sealed actuator internal clutching assembly 10.

Thus, there is provided a sealed actuator with internal clutchingassembly 10 which can drive in both directions, but when stopped willhold its position without back driving when subjected to a predeterminedload, e.g., a load many times greater than its dynamic range. Theactuator 10 also protects itself from damage from predetermined loads,e.g., very high loads, by means of the clutch that will disengage thedrive system allowing it to rotate (e.g., allowing the output shaft 16to rotate freely). The sealed actuator with internal clutching assembly10 is in a waterproof housing and can rotate in both directions for asmany revolutions as needed. The clutch is fully self contained in thehousing. The actuator has an output passthrough drive structure, e.g.,output shaft 16 arrangement, allowing it to drive a shaft or part fromeither side or both sides. The actuator can be mounted to a fixed partwith the only external moving part is the drive. The clutch system 12 ofthe sealed actuator with internal clutching assembly 10 also does notchange shape or height when it clutches, which is yet anothersignificant advantage.

The sealed actuator with internal clutching assembly 10 of the presentinvention can be, by way of non-limiting example, used with variousapplications including, but not limited to, vehicle rear spoilers, airdiffusers that move, active grill shutter systems, and underbodyenvironments with moving components. For example, the sealed actuatorwith internal clutching assembly 10 can be used in applications with arear spoiler such that under regular aerodynamics the rear spoiler staysin position, but under a predetermined load such as contact from pushingon the spoiler, the rear spoiler will be moved out of the way withoutdamage, e.g., to the actuator.

Referring now to FIG. 5, there is illustrated an example of applicationwith an active grill-type system. FIG. 5 is a partially broken awayperspective view of a vehicle engine compartment 100 is shown with anactive grille 102 connected. The active grille 102 has two or more vanes104 that are moveable between an open position and a closed position inorder to regulate airflow to the vehicle engine compartment 100. The twoor more vanes 104 as shown in FIG. 5 include a total of six vanes aspart of the active grille 102. However, any number of vanes can beimplemented including a single vane depending on the needs of aparticular application. The active grille 102 has a frame 106 and centerbar 108 that serve to both define a passage for airflow and provide amountable surface to which the two or more vanes 104 can rotate betweenthe closed position and open position. An electrically driven actuatoris connectable to the active grille 102 and configured to provide powerthat drives the vanes 104 between the open position and closed position.

FIG. 6 shows a partially broken away exploded perspective view of theactive grille 102 of FIG. 5. The two or more vanes 104 have at least onedriven vane 106 that is connected to an actuator 112 (e.g., sealedactuator with internal clutching assembly shown in FIGS. 1-4). Duringnormal operation of the active grille 102, the actuator 112 providespower to drive and move the at least one driven vane 106 between theclosed position and open position. Optionally, also connected to the atleast one driven vane 106 is a fail safe module 110 that is connectedbetween the at least one driven vane 106 and the actuator 112. The failsafe module 110 functions to disconnect the at least one driven vane 106and all of the other two or more vanes 104 from the actuator 112 in theevent of power failure or other disruption of the actuator 112 in orderto move the two or more vanes 104. It is desirable that the two or morevanes 104 are not in the closed position so that airflow through theactive grille 102 to the vehicle engine compartment 100 will not bedisrupted. When it is not desired to have airflow disrupted to thevehicle engine compartment 100, such as when the engine is already atoptimal heating conditions, preventing airflow to the vehicle enginecompartment 100 can result in engine overheating.

The description of the invention is merely exemplary in nature and,thus, variations that do not depart from the gist of the invention areintended to be within the scope of the invention. Such variations arenot to be regarded as a departure from the spirit and scope of theinvention.

What is claimed is:
 1. A sealed actuator with internal clutching forattachment to a vehicle component, comprising: an output shaft with anoutput gear and an output detent ring that are free to rotate about theoutput shaft; a moving detent ring slidably mounted on said output shaftand selectively radially locked to the output shaft for rotation withthe output shaft; first intermeshing ramped teeth on the output detentring in selective meshed engagement with second intermeshing rampedteeth on the moving detent ring; a wave spring mounted on said outputshaft providing a biasing force against said moving detent ring therebyselectively holding the second intermeshing ramped teeth of the movingdetent ring against the first intermeshing ramped teeth of the outputdetent ring, wherein upon receiving a predetermined level of high loadsufficient to overcome the biasing force of the wave spring, the firstintermeshing ramped teeth and the second intermeshing ramped teeth willcreate an axile force that overcomes the biasing force of the wavespring, that allows the moving detent ring to disengage from the outputshaft and allows the output shaft to rotate freely; a housing portionthat is fixed and sealed within which said output shaft is mounted; amain gear having selective torsional force transferring gear contactwith said output gear; a motor having a worm gear providing selectivetorsional force transferring gear contact with said main gear wherein,said worm gear is rotatable to transmit torque from said motor throughsaid main gear and said output gear to the outside of said housingportion via the output shaft.
 2. The sealed actuator with internalclutching of claim 1, wherein said output detent ring is mounted toselectively rotate on said output shaft.
 3. The sealed actuator withinternal clutching of claim 1, wherein said moving detent ring ismounted to selectively move axially on said output shaft.
 4. The sealedactuator with internal clutching of claim 1, wherein said moving detentring is locked radially with respect to said output shaft.
 5. The sealedactuator with internal clutching of claim 1, wherein said output shaftfurther comprises interlocking splines and said moving detent ringfurther comprises outer interlocking splines, wherein said moving detentring is locked radially on said output shaft by said outer interlockingsplines and respective interlocking splines.
 6. The sealed actuator withinternal clutching of claim 1, wherein said actuator does not changeheight when it clutches.
 7. The sealed actuator with internal clutchingof claim 1, wherein said actuator does not change shape or height whenit clutches.
 8. The sealed actuator with internal clutching of claim 1,wherein said output gear has circumferential segments in mesh withrecesses in said output detent ring.
 9. The sealed actuator withinternal clutching of claim 1, further comprising a first locking ringand a second locking ring located toward respective ends of said outputshaft to hold together said output shaft, output gear, output detentring, moving detent ring, and wave spring on said output shaft.
 10. Thesealed actuator with internal clutching of claim 1, wherein said motorfurther comprises a printed circuit board (PCB), said PCB correlatingwith vehicle communication networks and/or at least one sensor forcommanding energizing of said motor based upon predetermined conditions.11. The sealed actuator with internal clutching of claim 1, wherein saidhousing portion has a first half and a second half that are joined andheld together by fasteners to form a waterproof housing.
 12. The sealedactuator with internal clutching of claim 11, further comprising a firstseal and a second seal that are rings mounted toward the ends of saidoutput shaft to form a weather tight seal between said output shaft anda respective opening in said first half and second half.
 13. The sealedactuator with internal clutching of claim 12, wherein said motor andelectronics and connector contacts of said motor are located within acavity formed by a first motor cavity located in said second half and asecond motor cavity in said second half, and said main gear is locatedwithin a cavity formed by a main gear cavity located in said first halfand a second main gear cavity in said second half.
 14. The sealedactuator with internal clutching of claim 13, wherein said moving detentring, wave spring, output detent ring, output gear, output shaft, and afirst and second retaining ring are located in a first clutch assemblycavity and second clutch assembly cavity in said first and second half,respectively.
 15. The sealed actuator with internal clutching of claim1, wherein said output shaft is rotatable in both directions.
 16. Thesealed actuator with internal clutching of claim 1, wherein said sealedactuator with internal clutching provides an output pass through drivearrangement allowing said sealed actuator with internal clutching todrive a shaft or an external moving part from either end or both ends.17. The sealed actuator with internal clutching of claim 1, wherein saidsealed actuator with internal clutching is used for driving an activegrill system.
 18. A sealed actuator with internal clutching forattachment to a vehicle component, comprising: an output shaft with alower portion having a plurality of interlocking splines; an outputdetent ring rotatably mounted on a portion of said output shaft havingno interlocking splines; an output gear rotatably mounted on saidportion of said output shaft having no interlocking splines, where saidoutput gear is in mesh with said output detent ring, wherein the outputdetent ring and the output gear are free to rotate about the outputshaft; a moving detent ring slidably mounted on said lower portion ofsaid output shaft, where said moving detent ring is intermeshable withsaid output detent ring and the moving detent ring is selectivelyradially locked to the output shaft for rotation with the output shaft;first intermeshing ramped teeth on the output detent ring in selectivemeshed engagement with second intermeshing ramped teeth on the movingdetent ring; a wave spring mounted on said output shaft providing abiasing force against said moving detent ring thereby selectivelyholding the second intermeshing ramped teeth of the moving detent ringagainst the first intermeshing ramped teeth of the output detent ring,wherein upon receiving a predetermined level of high load sufficient toovercome the biasing force of the wave spring, the first intermeshingramped teeth and the second intermeshing ramped teeth will create anaxile force that overcomes the biasing force of the wave spring, thatallows the moving detent ring to disengage from the output shaft andallows the output shaft to rotate freely preventing damage to the sealedactuator with internal clutching; a housing portion that is fixed andsealed within which said output shaft is mounted; a main gear havingselective torsional force transferring gear contact with said outputgear; a motor having a worm gear providing selective torsional forcetransferring gear contact with said main gear wherein, said worm gear isrotatable to transmit torque from said motor through said main gear andsaid output gear to the outside of said housing portion via the outputshaft.
 19. The sealed actuator with internal clutching of claim 18,wherein said output detent ring is mounted to selectively rotate on saidoutput shaft.
 20. The sealed actuator with internal clutching of claim18, wherein said moving detent ring further comprises outer interlockingsplines, wherein said moving detent ring is locked radially on saidoutput shaft by said outer interlocking splines and respectiveinterlocking splines.
 21. The sealed actuator with internal clutching ofclaim 18, wherein said motor further comprises a printed circuit board(PCB), said PCB correlating with vehicle communication networks and/orat least one sensor for commanding energizing of said motor based uponpredetermined conditions.
 22. The sealed actuator with internalclutching of claim 18, further comprising a first seal and a second sealthat are rings mounted toward the ends of said output shaft to form aweather tight seal between said output shaft and a respective opening ina first half and second half of said housing portion, said first sealand a second seal when joined together forming a waterproof housing. 23.A sealed actuator with internal clutching for attachment to a vehiclecomponent, comprising: an output shaft with a lower portion having aplurality of interlocking splines; an output detent ring rotatablymounted on a portion of said output shaft having no interlocking splinessuch that said output detent ring is free to rotate on said outputshaft; an output gear rotatably mounted on said portion of said outputshaft having no interlocking splines, where said output gear is in meshwith said output detent ring, wherein the output detent ring and theoutput gear are free to rotate about the output shaft; a moving detentring slidably mounted on said lower portion of said output shaft, wherethe moving detent ring is selectively radially locked to the outputshaft for rotation with the output shaft; first intermeshing rampedteeth on the output detent ring in selective meshed engagement withsecond intermeshing ramped teeth on the moving detent ring; outerinterlocking splines formed on said moving detent ring interlockablewith said interlocking splines formed on said output shaft toselectively prevent radial movement of said moving detent ring; a wavespring mounted on said output shaft providing a biasing force againstsaid moving detent ring thereby selectively holding the secondintermeshing ramped teeth of the moving detent ring against the firstintermeshing ramped teeth of the output detent ring, wherein uponreceiving a predetermined level of high load sufficient to overcome thebiasing force of the wave spring, the first intermeshing ramped teethand the second intermeshing ramped teeth will create an axile force thatovercomes the biasing force of the wave spring, that allows the movingdetent ring to disengage from the output shaft and allows the outputshaft to rotate freely preventing damage to the sealed actuator withinternal clutching; a housing portion forming a weather tight seal; amain gear having selective torsional force transferring gear contactwith said output gear; a motor having a worm gear providing selectivetorsional force transferring gear contact with said main gear whereinsaid worm gear is rotatable to transmit torque from said motor throughsaid main gear and said output gear to the outside of said housingportion via the output shaft.